Operation: Bottom mount T3/T04E under way!

[KATwo40]

Ok, picked up a T25 bottom mount manifold (SSAC) from my buddy today. He had already modified it for an external WG. Here's what I have to work with.







After doing some quick-fitting on a spare engine I have here, it looks like it's going to be as simple as adapting a T3 flange onto the existing flange, at about a 15* angle. I'll make a plywood box to fit around the spare engine (exhaust side only) that will have the maximum clearance demensions for the strut tower, frame rail and steering shaft. That way, I can make sure it fits perfectly before hangin' it on the car.

More updates later in the week!

[Logan76]

Nice, you doing the welding yourself? goodluck.

[NateDogg]

I hope you're planning ahead for boost creep with that dump orientation.

[KATwo40]

I hope you're planning ahead for boost creep with that dump orientation.

LOL, yeah, that's the number one thing on the list. I'm going to hack it off, and make the WG exit perpendicular. That reverse angle crap isn't gonna cut it.

[KATwo40]

Got the T3 flange tacked on today. I'll do some final fitment tomorrow before welding it fully. I ended up just stacking it on top of the existing T2 flange. We'll see how that all fits. I'll post up pics in a couple days.

As for the WG port, that's gonna have to change. It's too close to the firewall/brake booster to be useful. Probably, I'll end up cutting off the little tube, capping it and tapping into the side of it near the turbo flange with a small tube, snaking it down toward the steering shaft. I'll figure all that out after the turbo placement has been set.

[KATwo40]

Ok, here are some mock-up pics.











You can see here that I had to grind away the motor mount bracket to clear the .50 a/r compressor housing. I'm not worried about it, since the engine torques in a direction that lifts the exhaust side, relieving a bit of stress from engine weight on that mount.



I'll get the flange fully welded Tuesday, then move on to relocating the WG.

[WDRacing]

Might as well cut the flange inbwteen the runners while you're modifying it.

[KATwo40]

Yep...it fits!





Clears the brake lines too!

[WDRacing]

If I do one, I'll turn the turbo flange a bit "off center" for better alignment. Did you port the hell out of the T2 flange?

WD

[KATwo40]

If I do one, I'll turn the turbo flange a bit "off center" for better alignment. Did you port the hell out of the T2 flange?

WD

Yeah, looking back, I should have rotated the flange just a bit, but it'll still clear.

There really isn't much room to port out the T2 flange because the collector itself is so tight/small. If I were to port it out, I would have a gaping hole between the collector and the T3 flange, inner portion.

Besides, if this manifold can take an SR sporting a big GT2871RS to 400whp, I'm sure it'll get me there on this turbo. The smaller collector should just make for a little faster spool up.

[KATwo40]

Oh yeah, should be able to use an SR hotpipe. That'll make life easy!

[crzycav86]

beautiful...

i'm so glad it worked out well.

[S13FX]

This is my favorite project. I was wondering why the DE guys havent been doing this. Especialy with the cost of that manifold heh.

[boznuttz]

That exact manifold should arrive at my house in the next week or so. Keep us posted on your setup and how it works! It looks great, and i might even like to try it as well.

[WDRacing]

Did you redo the WG angle?

[KATwo40]

Did you redo the WG angle?

Actually, I ended up leaving it as it was. All I have to do is re-route the brake booster vac line, bend the throttle cable just a tad (not enough to hurt it), then mount the WG up there. I'm most likely going to point the vent toward the front of the car, then run the tube (stainless) over the top of the last two runners, down between the manifold and strut tower, then down the back.

If I remove the A/C line, I'll be able to run it straight out the back, but I haven't decided if I am keeping A/C or not.

[daconkiftador]

very interesting, keep up the good work!

[Neejay]

I wish there was a semi-cheap solution for us SOHC guys...*sigh*

[KATwo40]

Thanks for all the comments. I'll keep everyone posted as to how well it works. Next week I'll finish up the IC pipes, downpipe and oil lines. Should be up and runnin' by next weekend.

[KATwo40]

Oil lines are on, downpipe is finished.

Man that DP was a cinch to make! The only issue is that I had to use a flux core mig welder (no argon gas), so it's a messy lookin' DP. The welds themselves are ok, but the flux core wire splatters EVERYWHERE, regardless of heat and wire speed.

But hey, it's a loaner from the boys over at Blindside Imports (the cheap T3/T04E place) and I can't complain. Quite generous of my buddy Todd to lend it to me.

I'll post up pics tomorrow of the DP and oil drain. Still waiting on 2 stinkin' silicone couplers to arrive so I can wrap up the IC pipes.

[KATwo40]

Last night I welded the O2 bung in the wrong place, so I had to hack out that part of the downpipe and re-do it.

So, here's the messy little bugger. Keep in mind, this is just a template for a full stainless mandrel bent pipe. I have access to a place that'll bend one for me, but I have to make the basic shape, first.

So, here we go!

[WDRacing]

Next time just use vacuum vent hose, it'll stay bent as a jig.

But that DP really isn't that bad. Its big enough to not really effect flow anyway. I'd keep it.

WD

[Logan76]

I actually think that DP look's good. esp. if your not that experienced of a welder...

[KATwo40]

Heh, thanks for the compliments. I'm totally a noob welder (no joke), but at the same time, I'm really anal about fabrication asthetics.

I'm so used to seeing all these beautiful tig jobs, so this flux core mig job is like "OMG I fuggzored it up!"

Maybe someday I'll buy a tig.

The inside of the pipe is pretty freakin' smooth. I had just enough penetration to mark the inside, but not drip through.

That being said, maybe I'll take WD's advice and keep it. Maybe just header wrap it? *grin*

Should be all finished tomorrow, so long as those darned IC couplers come in. I hate waiting on stuff like that.

[Logan76]

heh waiting on a few couplers sucks hardcore...I would be anxious as hell.

[daconkiftador]

i cant wait for more updates!!

lol

[eazye2000]

Looks like this may be a project I will be taking on myself here in the near future.. I have a Garrett GT28RS with .86AR right now. I'm looking to go T3 but with the cost of a decent manifold, and reading this, I'm about ready to attempt to tack on a T3 flange and go balls to the wall. I'll have to get in touch with you KATwo40 and talk about this. Exchange idea's.. I'm kinda excited about saving $600+ on a mani!

[WDRacing]

Screw Tig...just get a gas shielding mig setup. I love mine...

[KATwo40]

Screw Tig...just get a gas shielding mig setup. I love mine...

I'm not opposed to this idea.

[KATwo40]

Looks like this may be a project I will be taking on myself here in the near future.. I have a Garrett GT28RS with .86AR right now. I'm looking to go T3 but with the cost of a decent manifold, and reading this, I'm about ready to attempt to tack on a T3 flange and go balls to the wall. I'll have to get in touch with you KATwo40 and talk about this. Exchange idea's.. I'm kinda excited about saving $600+ on a mani!

Hit me up anytime. I have the hookup on T3/T04E's for CHEAP with a warranty.